JLG 1230ES Service And Maintenance Manual
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JLG 1230ES Service And Maintenance Manual

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Service and Maintenance Manual
Model(s)
1230ES
P/N - 3121222
June 22, 2017
AS/NZS

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  • Page 1 Service and Maintenance Manual Model(s) 1230ES P/N - 3121222 June 22, 2017 AS/NZS...
  • Page 2 NOTES:...

  • Page 3: General

    Every effort should be made to relieve any system • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS pressure prior to disconnecting or removing any por- STOWED IN THEIR PROPER PLACE. tion of the system. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS. 3121222 – JLG Lift –...

  • Page 4: Revision Log

    Manual Revised ..... . February 8, 2017 Manual Revised ......June 22, 2017 – JLG Lift – 3121222...

  • Page 5: Table Of Contents

    Lubrication Specifications ........... . 2-7 3121222 – JLG Lift –...
  • Page 6 Changing Hydraulic Oil ............2-7 SECTION 3 - THEORY OF OPERATION - 1230ES 3.1 OVERVIEW .
  • Page 7 6.3 MAST COVER PLATE - INSTALLATION..........6-2 3121222 – JLG Lift –...
  • Page 8 Hydraulic Cylinder Assembly Testing ......... . 6-17 SECTION 7 - JLG CONTROL SYSTEM 7.1 ELECTRONIC CONTROL SYSTEM .
  • Page 9 9.12 HYDRAULIC SCHEMATIC ............9-42 3121222 – JLG Lift –...
  • Page 10 1230ES Lift Cylinder Internal Components - Lower End ....... .6-13...
  • Page 11 HD/HDP Unlocking Contacts ........... . .9-13 9-12. 1230ES - Location of Component X-Connectors on Machine......9-20 9-13.
  • Page 12 Power Module - J2 (1001092456 Power Module ONLY) ....... .9-36 viii – JLG Lift – 3121222...

  • Page 13: Section 1 - Machine Specifications

    CE/AUS - Indoor Only - 45 lb. force - 200 N (Platform fully extended with Maximum load) AUS w/CWT - Indoor - 89 lb. force - 400 N AUS w/CWT - Outdoor - 45 lb. force - 200 N 3121222 – JLG Lift –...

  • Page 14: Operating Specifications

    ( 323mm x 100mm) Batteries - AGM (each) 69.2 lb. 31.4 kg Max Tire Load 2500 lb. (1134 kg) Batteries - AGM - Combined 276.8 lb. 125.6 kg Wheel Bolt Torque 120 ft lb (163 Nm) – JLG Lift – 3121222...

  • Page 15: Lubrication

    SAE viscosity index of 140. When temperatures remain below 20°F (-7°C), JLG recommends the use of Mobil DTE13. Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable vis- cosities.

  • Page 16: Oil Check Procedure

    Figure 1-1. Hydraulic Oil Check Procedure NOTE: Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accord- ingly. – JLG Lift – 3121222...

  • Page 17: Torque Chart (Sae Fasteners - Sheet 1 Of 7)

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N Loctite® P/N...

  • Page 18: Torque Chart (Sae Fasteners - Sheet 2 Of 7))

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)) – JLG Lift – 3121222...

  • Page 19: Torque Chart (Sae Fasteners - Sheet 3 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7) 3121222 – JLG Lift –...

  • Page 20: Torque Chart (Sae Fasteners - Sheet 4 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7) – JLG Lift – 3121222...

  • Page 21: Torque Chart (Metric Fasteners - Sheet 5 Of 7))

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) 3121222 – JLG Lift –...

  • Page 22: Torque Chart (Metric Fasteners - Sheet 6 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 1-10 – JLG Lift – 3121222...

  • Page 23: Torque Chart (Metric Fasteners - Sheet 7 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 3121222 – JLG Lift – 1-11...
  • Page 24 SECTION 1 - MACHINE SPECIFICATIONS NOTES: 1-12 – JLG Lift – 3121222...

  • Page 25: Section 2 - General Service Information

    JLG equipment mechanic as a Preparation, Inspection, and Maintenance person who has successfully completed the JLG Service Training School for the subject JLG product model. Ref- It is important to establish and conform to a compre- erence the machine Service and Maintenance Manual...

  • Page 26: 2.2 Preventive Maintenance And Inspection Schedule

    Service and Maintenance Manual and Owner, Dealer, or User Qualified JLG Mechanic Inspection rental delivery. applicable JLG inspection form. In service for 3 months; or Out of service for a Frequent Service and Maintenance Manual and period of more than 3 months; or Purchased...

  • Page 27: Preventive Maintenance & Inspection Schedule

    1, 9 Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7 Hydraulic Fluid *** Electrical Connections Instruments, Gauges, Switches, Lights, Horn GENERAL Operation & Safety Manual in Storage Box ANSI & EMI Handbooks in Storage Box 3121222 – JLG Lift –...

  • Page 28: Maintenance And Inspection Table Codes

    Grease and Lubricate to Specifications Function Test of All Systems Paint and Appearance Notify JLG of change in Machine Ownership Change only when serviced, Fill half full. Replace when system brush wear indicator warning is activated. *** Every two years, drain and remove hydraulic oil reservoir , clean pick-up screen, refill with fresh hydraulic fluid.

  • Page 29: 2.3 Servicing And Maintenance Guidelines

    1. Elevate platform/outer mast (1) approximately 3 ft. (1m). 2. Place (JLG P/N-1001094004) mast support tool (2) between the Pressure-Fit Parts mast and the front frame by hooking the bracket (3) over the When assembling pressure-fit parts, use an “anti-seize”...

  • Page 30: Bearings

    Disassemble and reassemble parts on clean work sur- face. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly. – JLG Lift – 3121222...

  • Page 31: 2.4 Lubrication Information

    Hydraulic Oil tem can cause wear or damage to the components and For best performance, JLG recommends the use of ISO- generally results in faulty operation. Every precaution Vg grade 15 oil with a viscosity range between 15-250 must be taken to keep hydraulic oil clean, including SUS at 100 degrees F (32-54 cST at 40 degrees C).
  • Page 32 SECTION 2 - GENERAL SERVICE INFORMATION NOTES: – JLG Lift – 3121222...

  • Page 33: Section 3 - Theory Of Operation - 1230Es

    These resistors are approximately In Ground Mode, all visual indicators (LED) in the Platform 120 Ohms. On a JLG aerial work platform, this is typically in are off. In fact, the Platform Control Box may be entirely the platform and in the chassis.

  • Page 34: Basic Electronic Module Connections

    SECTION 3 - THEORY OF OPERATION - 1230ES Platform Control Station X050 Ignition E STOP Ground PLATFORM BOARD X047 X048 CAN Low CAN High X046 X108 X105 120Ω X106 FOOTSWITCH ACCY Ignition MODULE Ground (OPTIONAL) X107 CAN High CAN Low...

  • Page 35: Controls & Sensors

    SECTION 3 - THEORY OF OPERATION - 1230ES CONTROLS & SENSORS 3.5°, the control system considers the machine tilted. In other markets, the vehicle is considered Tilted if the vehi- cle tilt angle front to back is greater than or equal to 3.0°...

  • Page 36: Personalities

    SECTION 3 - THEORY OF OPERATION - 1230ES Line Contactor Right Field Winding Armature Right Left MOSFET Armature Armature Field Shunt Left Field Winding MOSFETS Power Module Figure 3-3. Drive Motors Schematic - 1001092456 (ZAPI) Power Module The Field Windings also provide direction reversal for trac- Interlocks tion.

  • Page 37: Pump/Lift/Mast

    SECTION 3 - THEORY OF OPERATION - 1230ES PUMP/LIFT/MAST An electrically driven hydraulic pump provides hydraulic pressure to actuate the steering and lift up. Lift down is "powered" by gravity. The lift actuator is a three stage PLA T FO R M hydraulic cylinder.

  • Page 38: Personalities

    SECTION 3 - THEORY OF OPERATION - 1230ES larly, the MOSFET are On continuously (100% Duty Cycle) STEER to apply all available Battery power to the pump motor (as in Lift Up at full speed). Steering is actuated by a double action hydraulic cylin- der.

  • Page 39: Section 4 - Base Components

    2. Steering Linkage Assembly 5. Static Strap 8. Right Side (Battery Tray) Door 3. Drive Motor/Spindle Assemblies 6. Steer Cylinder Assembly 9. Rear Wheel Assembly NOTE: Base assembly shown without base top weldment for illustrative purposes only. 3121222 – JLG Lift –...

  • Page 40: Base Frame Covers

    6. Door Latch Pin 4. Washer(s) NOTE: Before assembly lubricate (coat) the door hinge pins with Loctite Moly Paste Lubricant (JLG Part No. - 3020039). Lift door (1) into cutout in base frame (2), align the upper and lower hinge pins on the door with the holes in the upper and lower base frame hinge (4) and lower door until set.

  • Page 41: Wheels And Tires - Drive And Rear

    4. Wheel lug nuts should be torqued after the first wheels. The proper procedure for attaching wheels is as 50 hours of operation and after each wheel follows: removal. Check torque every 3 months or 150 hours of operation. 3121222 – JLG Lift –...

  • Page 42: Rear Wheel Hub - Installation

    4. Install cotter pin, if necessary nut may be backed off to nearest slot, if more than 1/2 the cotter pin hole is visible, the nut may be tightened slightly to get the cotter pin installed. – JLG Lift – 3121222...

  • Page 43: Steering Linkage Assembly - Installation

    On final assembly apply Loctite #242 to screw threads of the steer cylinder Cross Link Anchor pin keeper screw. On final assembly, apply Loctite #271 to the knuckle lug to spindle attach screws and torque to 70 ft. lbs (97 N,m) 3121222 – JLG Lift –...

  • Page 44: Steer Cylinder - Servicing

    NOTE: (a) On final assembly torque cylinder head (Gland) to 500Nm (112 ft. lb.) (b) Apply Loctite #242 to threads before final assembly and torque to 260Nm (55 ft. lb.) Refer to Section 3.7, STEER - Theory of Operation for more detailed information on Steer Cylinder System. – JLG Lift – 3121222...

  • Page 45: Steer Cylinder Disassembly

    3. Using the proper spanner wrench, remove the piston from the cylinder rod. 4. Slide the cylinder head (gland) off the piston end of the cylinder rod. 3121222 – JLG Lift –...

  • Page 46: Hydraulic Cylinder Component Inspection

    SECTION 4 - BASE COMPONENTS Hydraulic Cylinder Component Inspection Steer Cylinder - Assembly NOTE: Prior to cylinder assembly, ensure the proper JLG Cylinder Rod seal kits are used, see the JLG Parts Manual. There should be no scratches or pits deep enough to catch the fingernail.
  • Page 47 Oil level should be between min. and max. on the side of the tank. Cylinder Head Installation 2. Spanner Wrench (48mm - 1. Cylinder Head (Gland) 1.89" Dia., 5mm Pin Dia.) 3121222 – JLG Lift –...

  • Page 48: Drive Motor/Spindle Assembly - Installation

    On final assembly, apply Loctite #271 to the spindle to knuckle lug attach screws and torque to 70 ft. lbs (97 N,m) (b) Coat king pin with moly paste lubricant prior to installation of spindle assembly. 4-10 – JLG Lift – 3121222...

  • Page 49: Wheel Drive Assembly - Servicing

    High resistance can signal corro- sion, improper crimps, damaged connectors, damaged cabling, or an open field winding. 3121222 – JLG Lift – 4-11...

  • Page 50: Roll And Leak Testing

    NOTE: Due to the small air volume inside this Torque-Hub, it will pressurize to 10 psi very quickly. If the pressure becomes excessive in the unit the seals will be destroyed. Figure 4-3. Drive Motor Power Harness Routing 4-12 – JLG Lift – 3121222...

  • Page 51: Wheel Drive Brake - Manual Disengage Procedure

    The size of The electric wheel drive assemblies are mounted indepen- the Cover Plate Bolts is (#8 -32UNC x .500 inches tent of each other on the base frame at the front of the long) machine. 3121222 – JLG Lift – 4-13...
  • Page 52 4. Remove the drive wheel mounting lugs and workbench. remove the wheel(s). Wheel Drive Assembly - Removal 10. Drive Motor Assembly 12. Drive Motor Mounting Bolts 11. Mounting Bolt Washers NOTE: Removal same for left and right drive motor. 4-14 – JLG Lift – 3121222...

  • Page 53: Drive Motor Disassembly

    9. Use an arbor press or a bearing puller to remove the armature from the commutator end head assembly. 10. Remove the snap ring (6) and bearing (7) from the commutator end head. Discard the bearing. 3121222 – JLG Lift – 4-15...

  • Page 54: Drive Motor Inspection And Servicing

    250-300 in-lb [28.2-33.9 N-m]. Verify field resis- tance using a suitable ohmmeter per the appro- priate motor specification. Verify that the field is electrically isolated from the frame using a dielectric tester. Replace as necessary. 4-16 – JLG Lift – 3121222...

  • Page 55: Drive Motor - Reassembly

    2 screws. small amount of RTV Silicone Sealant. 11. Reinstall motor per instructions - See Page 4-28. Figure 4-9. Bearing Replacement Procedure 3121222 – JLG Lift – 4-17...

  • Page 56: Main Gear Box Disassembly

    This bearing will have to be replaced afterwards. 7. Using a screwdriver, remove Spiral Retaining Ring (27). 8. Pull Hub Subassembly off of the Spindle (1) Subassembly. 4-18 – JLG Lift – 3121222...

  • Page 57: Input Carrier Disassembly

    9. Remove the three Planet Shafts (6) from the Input Carrier. NOTE: The Planet Shafts (6) are held in with a press fit. To avoid damage to the parts, use an arbor or hydraulic press to remove the Planet Shafts (6). 3121222 – JLG Lift – 4-19...

  • Page 58: Hub - Disassembly

    NOTE: This Lip Seal (16) is also held in with a press fit. Remove the Lip Seal only if the hub or seal needs to be replaced. The Lip Seal will most likely become damaged during removal. Try not to damage the hub bore. 4-20 – JLG Lift – 3121222...

  • Page 59: Spindle Disassembly

    NOTE: This bearing is held in with a press fit. You will need to pry against the Spindle (1) to remove it. A new bearing should be used when the unit is reassembled. 9. Press out the Main Bushings (12) at the top of the Spindle (1) neck. 3121222 – JLG Lift – 4-21...

  • Page 60: Spindle Sub-Assembly

    9. Insert an Output Planet Shaft (10) into the Planet Shaft hole of the Spindle (1) and through the bores of the Thrust Washers (25) & (32) and the Planet Gear (9). 10. Before pressing the Output Planet Shaft (10) into the Spindle (1), make sure the gear spins freely. (continued next page) 4-22 – JLG Lift – 3121222...
  • Page 61 13. Turn the Spindle (1) over so that the carrier end is down. 14. Using a flat plate or rod, press the Motor Shaft Seal (17) into the center bore so that it is flush with the face of the Spindle (1). 3121222 – JLG Lift – 4-23...

  • Page 62: Hub Sub-Assembly

    Seal into the bore with a rubber mallet before pressing. 3. Flip the Hub (2) over 4. Using the appropriate pressing tool (T-174356), press the Main Bearing (15) into the bore until it bottoms out. 4-24 – JLG Lift – 3121222...

  • Page 63: Input Carrier Sub-Assembly

    The other three holes are for a different gear ratio. 9. Using the appropriate retaining ring pliers put a Retaining Ring (18) into the groove of each Input Planet Shaft (6). NOTE: Do not overstress the Retaining Rings (18). 3121222 – JLG Lift – 4-25...

  • Page 64: Main Gear Box Sub-Assembly

    8. Install Retaining Ring (27) into the groove on the OD of the Spindle (1) carrier. This is a Spiral Retaining Ring so it will not require pliers. You will need to pull the Retaining Ring (27) apart and work it into the groove. (continued next page) 4-26 – JLG Lift – 3121222...
  • Page 65 NOTE: Make sure that both the Cover Thrust Washer (21) and the Cover (11) have good clean surfaces for the Loctite to properly adhere. 14. Center the Cover (11) in the hub bore so that the "JLG" logo is up. Push it into the bore. 15. Install the Cover Retaining Ring (19) into the groove of the Hub Sub-assembly.

  • Page 66: Motor Assembly

    2. Install the 2 Motor Mounting Bolts (M7) and Washers (M8). Tighten to 9-11 ft-lbs. 3. Connect the end of the power cable to the power controller, route cable per instruction in Figure 4-3. 4. Fill the gearbox with oil, See Oil Type & Capacity on Page 4-12. 4-28 – JLG Lift – 3121222...

  • Page 67: Hydraulic Pump/Motor/Valve Assembly - Service Procedure

    Ground Reference is 24V. If not, examine the issues within Open-Circuit Pump Motor. This The following difficulties can be examined using the JLG voltage should ramp to approximately 0V when Analyzer, a voltmeter, and simple hand tools. Unless other- Lift Up is operated from Ground Mode.

  • Page 68: Main Electrical Power Connections - (1600346 - Sevcon Power Module)

    2. Left Side Batteries 7. Left Drive Motor 3. Power Module 8. Battery Power Quick-Disconnect 4. Main Power Contactor Relay 9. To Battery Charger 5. Hydraulic Pump Motor 10. To Charger or Inverter (Option, If Equipped) 4-30 – JLG Lift – 3121222...

  • Page 69: Main Electrical Power Connections - (1001092456 - Zapi Power Module)

    2. Left Side Batteries 7. Left Drive Motor 3. Power Module 8. Battery Power Quick-Disconnect 4. Main Power Contactor Relay 9. To Battery Charger 5. Hydraulic Pump Motor 10. To Charger or Inverter (Option, If Equipped) 3121222 – JLG Lift – 4-31...

  • Page 70: Pump Components

    NOTE: During reassembly of the pump/motor assembly, lubricate all seals and o-rings with JLG recom- mended hydraulic fluid. Also keep all internal metal parts clean and coated with hydraulic fluid to prevent surface corrosion.

  • Page 71: Hydraulic System Pressure Settings

    33 Ohm Steer - Left/Right Solenoid Figure 4-13. Relief Pressure Setting Locations 1. Pump Valve Body 4. Main Pressure Relief 2. Steering Right Pressure Relief 5. Pressure Gauge Check Port 3. Steering Left Pressure Relief 3121222 – JLG Lift – 4-33...

  • Page 72: Pump/Motor/Valve Assembly - Removal/Installation

    2. Disconnect the pump motor power cables from the power terminals on the side of the motor housing. 4-34 – JLG Lift – 3121222...
  • Page 73 5. Tank Oil Ring Seal 13. Right Steer Pressure Relief 6. Hydraulic Pump 14. Lift/Steer Valve Body 7. Pick-Up w/Filter Screen 15. Lift Selenoid Valve 8. Return Flow Filter/Diffuser 16. Left/Right Steer Selenoid Valve 3121222 – JLG Lift – 4-35...

  • Page 74: Motor Cover/Motor Installation

    Check brushes for wear, replace if necessary. Once complete, reassemble for operation, do not overtighten the motor cover bolts into the aluminum valve body, 8 Nm (70 in. lb.). 4-36 – JLG Lift – 3121222...

  • Page 75: 4.10 Pot Hole Protection System

    16. Left PHP Bar 13. Left Side Counterbalance Link 17. Spacer Tube and Torsion Springs PHP Pin and Flange Bearing Installation 1. PHP Link Plate Pin 18. Flange Bearing 19. PHP Counterweight Link 20. Retaining Ring 3121222 – JLG Lift – 4-37...
  • Page 76 (b) Apply Loctite #222 to mounting block screw threads on final tightening. (c) Hook spring through slot in frame and the other end around the counterweight lug, then slide the attach pin through the frame, spring, counterweight, tube spacer, install the pin retaining ring. 4-38 – JLG Lift – 3121222...
  • Page 77 (b) Apply Loctite #222 to mounting screw threads on final tightening. (c) Hook spring through slot in frame and the other end around the counterweight lug, then slide the attach pin through the frame, spring, counterweight, tube spacer, install the pin retaining ring. 3121222 – JLG Lift – 4-39...
  • Page 78 SECTION 4 - BASE COMPONENTS NOTES: 4-40 – JLG Lift – 3121222...

  • Page 79: Section 5 - Control Components

    9. Main Contactor Power Relay 2. Ground Control Station 6. Right Side Batteries 10. Elevation Cut-Back Sensor 3. Manual Brake Release Switch 7. Ground Alarm 11. Left Side Batteries 4. Battery Charger or Inverter/Charger 8. Power Module 3121222 – JLG Lift –...

  • Page 80: Control Components - Service

    3. Switch Mounting Block 1. Beacon Assembly 2. Attach Screws Note: Located on right-front of machine frame behind drive wheel assembly Note: Located on base frame just above the left rear wheel. next to mast. – JLG Lift – 3121222...

  • Page 81: Manual Brake Release Switch

    6. Breaker Box Base 3. Breaker Assembly 7. Breaker Box Shield 4. Mounting Screw Plugs 8. Box to Frame Mounting Screw - Nuts and Washers Note: Located on left rear of machine, just above the machine nameplate. 3121222 – JLG Lift –...

  • Page 82: Traction System

    Investigate for to Drive from Platform Mode. Refer to the Sec- crushed and burned cables. Note if the drive tion 5 for explanation of the JLG Analyzer Help motor smells burned. Messages. 5. Open-Circuit Motor Field 2.
  • Page 83 2. Left Side Batteries 7. Left Drive Motor 3. Power Module 8. Battery Power Quick-Disconnect 4. Main Power Contactor Relay 9. To Battery Charger 5. Hydraulic Pump Motor 10. To Charger or Inverter (Option, If Equipped) 3121222 – JLG Lift –...
  • Page 84 2. Left Side Batteries 7. Left Drive Motor 3. Power Module 8. Battery Power Quick-Disconnect 4. Main Power Contactor Relay 9. To Battery Charger 5. Hydraulic Pump Motor 10. To Charger or Inverter (Option, If Equipped) – JLG Lift – 3121222...
  • Page 85 This situation can be detected by elevating the vehicle's front wheels and engaging drive (plat- form stowed). Under DIAGNOSTICS - TRACTION, the JLG Analyzer's ARM CUR display (Armature Current Reading) will hover around 350A. The FLD CUR display (Field Current Reading) will hover around 40A.

  • Page 86: Power Module - P/N-1600346

    1230ES Scissors built starting in mid year 2010 replaced the Sev- 3. Torque the terminal bolts to 5 ft lb. (7 Nm). con Power Module (P/N-1600473) with the ZAPI Power Module (P/ 4.
  • Page 87 MOSFET transistors between these ter- should measure between 110 - 130 Ohms. minals that should be high-impedance when the module is un-powered. Place the Black meter lead on +B and the Red meter lead on F1 / F1. 3121222 – JLG Lift –...

  • Page 88: Power Module Diagnostics

    The Power Module has the ability to detect many fault sce- faulty Power Module. narios and communicate them to the JLG Analyzer. Useful c. 8 Flashes on Power Module. diagnostic information can also be determined from the 6.
  • Page 89 Ground Control Box and Power Mod- range or corrupt personality setting. ule. Recycle power to clear difficulty. b. Enter Access Level 1 on the JLG Analyzer, re- b. May indicate harness difficulty or a faulty select Model, and cycle EMS after 5 seconds.

  • Page 90: Power Module - P/N-1001092456

    1. Turn machine power off and disconnect the bat- teries. 1230ES Scissors built starting in mid year 2010 replaced the Sev- 2. Locate and remove the power module from the con Power Module (P/N-1600473) with the ZAPI Power Module (P/ machine.

  • Page 91: Zapi Power Module Electrical Evaluation

    – T Left and Right Negative Armature (X8) – P Negative Pump Connection P/N - 1001092456 To Motor Fields Wired in Series (X9) ZAPI Power Module - "HEALTH" (Status LED) LT MFR Field Wires (X10) 3121222 – JLG Lift – 5-13...

  • Page 92: Ground Control Module - Service Procedure

    6. Remove the two screws inside the control box that affix the printed circuit board to the control box. 7. Replace the printed circuit board and reassem- ble the ground control box. 5-14 – JLG Lift – 3121222...
  • Page 93 6. Control Functions Decal 17. Keyswitch - Ground/Platform/OFF Control 7. Hourmeter 18. Emergency Stop Switch 8. Blank Plug 19. Tilt Module 9. Unused 20. Battery LED Indicator Connector Harness (X010) 10. Controls/Indicators Mounting Plate 3121222 – JLG Lift – 5-15...

  • Page 94: Ground Control Station

    SECTION 5 - CONTROL COMPONENTS Tilt Sensor, JLG P/N 1810140 and 1001114933: 1. Ground Control Station 2. Tilt Sensor (JLG P/N 1810140 or 1001114936) Figure 5-45. Tilt Sensor Location Tilt Sensor Removal: 1. Tilt Sensor (JLG P/N 1810140 or NOTE: Refer to Figure 5-46., Tilt Sensor Removal for num- 1001114936) bers in parenthesis.

  • Page 95: Platform Control Station - Service Information

    2. Place the platform control box on a suitable control box where the drive/lift select switch is work bench. located. 3. Loosen and remove the long through bolts that hold the two side control housings together. 3121222 – JLG Lift – 5-17...
  • Page 96 2. Board Attach Screws ness Connector 4. Front Button Switch to Circuit Board Ribbon Cables 1. Disconnect the upper to lower box harnness connector from the printed circuit board, and unplug the lift/drive switch blade terminals. 5-18 – JLG Lift – 3121222...

  • Page 97: Lower Control Box - Component Replacement

    3. Reverse steps to install. NOTE: Note wiring connections and routing when taking apart. Joystick Control - Installation 1. Joystick Assembly 3. Lower Control Box 2. Attach Screws 3121222 – JLG Lift – 5-19...

  • Page 98: 5.8 Battery/Battery Charger

    CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. MUST BE USED. THE USE OF NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFOR-...

  • Page 99: Battery Installation

    5. Locking Nut LED/Power/Interlock Cable - Identification 3. Hold Down Clamp 1. Charger Interlock Cable 3. LED Indicator, Battery 2. DC Power Cable to Batteries Temp. Sensor Cable See Section-1 of this manual for battery specifications. 3121222 – JLG Lift – 5-21...

  • Page 100: Battery Charger Troubleshooting

    3. This fault will clear automatically when the low battery voltage problem is rectified. 4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per 5-22 – JLG Lift – 3121222...
  • Page 101 - 6V per 6V battery, good. 12V per 12V string/battery. 6. If all battery connections are good, an internal fault has been detected and the charger must be brought to a qualified service depot. 3121222 – JLG Lift – 5-23...

  • Page 102: Battery Algorithms

    Trojan 30/31XHS The charger is pre-loaded with programming algorithms US Battery USB2200 for the specific batteries detailed in Table 5-5, Battery Algorithms. Contact JLG if your specific battery model is T105 DV/DT CP not listed. Trojan T105 tapped Each time AC power is applied with the battery pack not...

  • Page 103: Battery Charger/Inverter (Option) - Installation

    For further specification and troubleshooting information refer to the manufacturers’ Charger/Inverter Owner’s Guide shipped with the machine. Publication - RM1024- JLG - Part # 3128406. Also see Section 8 - Figure 9-20., Battery Charger/Inverter Electrical Connection Schematic for more detailed con- nection information.
  • Page 104 SECTION 5 - CONTROL COMPONENTS NOTES: 5-26 – JLG Lift – 3121222...

  • Page 105: Section 6 - Mast Components

    SECTION 6 - MAST COMPONENTS SECTION 6. MAST COMPONENTS MAST COMPONENTS OVERVIEW Figure 6-1. Mast Components. 1. Platform Assembly 4. Mast Assembly 2. Tool Tray 5. AC Power Receptacle 3. Mast Cover Plate 6. Manual Storage Box 3121222 – JLG Lift –...

  • Page 106: Platform Tool Tray - Installation

    MACHINES ONLY on page 9-39) for receptacle wiring connections of MAST COVER PLATE - INSTALLATION available AC plug types. Mast Cover Plate Installation 1. Mast Cover Plate 3. Top of Mast Assembly 2. Rivet Nuts – JLG Lift – 3121222...

  • Page 107: Mast Assembly - Components

    The slide pads are available in two thicknesses: JLG P/N-1001092165 - 9,7mm thick - round notch on ends JLG P/N - 4700042 - 8,7mm thick - NO round notch on end Always use the 1001092165 slide pad unless mast tube clearances prevent Figure 6-2.

  • Page 108: Platform Assembly

    NOTE: It may be necessary to pull down or push up on the 1. Sling Position -1 3. Lifting Ring/Hook rear of the platform to keep the platform level while 2. Sling Position - 2 4. Manual Descent Valve Location lifting it off of the mast assembly. – JLG Lift – 3121222...

  • Page 109: Platform Installation

    Once clear of the mast assembly, assembly. move to a suitable area for later assembly. 2. Before lowering the platform assembly onto the mast, be certain the electrical cables for the AC receptacle box and platform control station are 3121222 – JLG Lift –...

  • Page 110: Mast Assembly

    11. If operation is OK, reinstall the mast section top cover. Figure 6-6. Mast - Installation (Front of frame shown cutaway for illustrative purposes only) 1. Mast Assembly 2. Fastening Hardware – JLG Lift – 3121222...

  • Page 111: Mast Removal

    This der #1, still attached to the base frame. method also requires the AC receptacle box and the platform control box cable to be disconnected and feed down through the mast with the power-trak. 3121222 – JLG Lift –...

  • Page 112: Mast Disassembly

    2. Using suitable lifting equipment and strap, slide 9. Lift the mast assembly free of the frame, place the cylinder assembly out the bottom of the on a suitable workbench for disassembly. mast assembly, place on a suitable workbench. – JLG Lift – 3121222...

  • Page 113: Mast - Reassembly

    1.Attach Screws 3. Power-Trak Guide on ends 2.Power-Trak Hanger Bracket (a) JLG P/N - 4700042 - (8,7 mm thick) - NO round notch on end NOTE: (a) Remove bracket from slot in mast and remove power-trak harness from the mast.

  • Page 114: Mast Installation

    (See Figure 6-7.) Check the side to side play between the mast mount and the frame mount, shim equally to both sides until side to side play is removed. Install the mast mounting bolts, nuts, and washers, with the nuts inboard. 6-10 – JLG Lift – 3121222...
  • Page 115 (b) An extra washer may be required to space the screw away from the RED manual descent button on the lift cylinder. Torque mast mounting bolts to 62 ft. lbs. (88 Nm), tighten in an X (cross) tightening pattern. 3121222 – JLG Lift – 6-11...

  • Page 116: Multi-Stage Hydraulic Cylinder - Cylinder Bleeding Procedure

    If necessary, check the lift system hydraulic pres- sure setting. Cycle the mast up and down a few times then check at the top and bottom of the mast for any hydraulic oil leaks. 6-12 – JLG Lift – 3121222...

  • Page 117: Multi-Stage Hydraulic Cylinder - Servicing

    Refer to Section 3.6, PUMP/LIFT/MAST - Theory of Operation for more detailed information on Hydraulic System. Overview The hydraulic cylinder for this machine is a multi-stage - three cylinder design. Figure 6-15. 1230ES Lift Cylinder Internal Components - Top End 1. Cyl. #3 - Gland 7. Cyl. #1 - Piston Retaining Ring 2.
  • Page 118 SECTION 6 - MAST COMPONENTS Figure 6-16. 1230ES Lift Cylinder Internal Components - Lower End 1. Extend Port (a) 13. Cyl. #2 - Cap O-Ring Seal 2. Return Port 14. Cyl. #2 - Joint O-Ring Seals 3. Proportional Lift Selenoid (b) 15.

  • Page 119: Hydaulic Cylinder - Disassembly

    2. Using the proper size wrench, (approx. 55mm - 2.165"), turn the valve block assembly counter- clockwise to remove it from the end of the cylin- der rod. 3121222 – JLG Lift – 6-15...

  • Page 120: Cylinder Rod/Gland - Removal

    WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BAR- REL SURFACES. 5. Carefully slide the rod assembly out of the cylin- der barrel and place on a clean surface prefera- bly a workbench. 6-16 – JLG Lift – 3121222...

  • Page 121: Hydraulic Cylinder Component Inspection

    SECTION 6 - MAST COMPONENTS Hydraulic Cylinder Component Inspection Hydraulic Cylinder - Assembly NOTE: Prior to cylinder assembly, ensure the proper JLG Cylinder Rod seal kits are used, see the JLG Parts Manual. There should be no scratches or pits deep enough to catch the fingernail.

  • Page 122: Hydraulic Cylinder Assembly Testing

    5. Install the rod attach cap to the tapered end of the cylinder rod and torque the cap to 200 Nm (45 ft. lb.). 6-18 – JLG Lift – 3121222...

  • Page 123: Section 7 - Jlg Control System

    SECTION 7 - JLG CONTROL SYSTEM SECTION 7. JLG CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM The top level menus are as follows: (Also see menu flow charts - Figure 7-1. and Figure 7-2.) To Connect the Hand Held Analyzer: HELP DIAGNOSTICS 1.

  • Page 124: Changing The Access Level Of The Hand Held Analyzer

    SECTION 7 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu Using the UP or DOWN arrow keys, enter the first digit of items may be offered; the password, 3. If for example you choose Personalities:...

  • Page 125: Machine Setup

    ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTI- LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COM- PONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/...
  • Page 126 SECTION 7 - JLG CONTROL SYSTEM – JLG Lift – 3121222...
  • Page 127 SECTION 7 - JLG CONTROL SYSTEM 3121222 – JLG Lift –...
  • Page 128 SECTION 7 - JLG CONTROL SYSTEM – JLG Lift – 3121222...
  • Page 129 SECTION 7 - JLG CONTROL SYSTEM 3121222 – JLG Lift –...
  • Page 130 SECTION 7 - JLG CONTROL SYSTEM – JLG Lift – 3121222...

  • Page 131: Machine Configuration Programming Information

    INFORMATION personality settings to return to default. NOTE: When configuring an 1230ES machine, the machine Shaded entries are not available for the selected configuration must be completed before any person- market.

  • Page 132: Zapi - 1001092456 Power Module Only

    SECTION 7 - JLG CONTROL SYSTEM Table 7-2. Machine Configuration Programming Information (1001115626-B) (Machines Equipped with ZAPI - 1001092456 Power Module Only) Market Default Setting Configuration Setting Description Digit Range 1230ES 1930ES (Set to your applicable ES 2030ES Model (Model #)

  • Page 133: Machine Personality - Adjustment Settings

    SECTION 7 - JLG CONTROL SYSTEM MACHINE PERSONALITY - ADJUSTMENT SETTINGS Table 7-4. Machine Personality Adjustment (1001115627-B) - Table 7-3. Machine Personality Adjustment (4150472-H) - Machines Machines Equipped with ZAPI (1001092456) Power Module Equipped with Sevcon (1600346) Power Module 1230ES...

  • Page 134: 7.4 Tilt Sensor Calibration

    SECTION 7 - JLG CONTROL SYSTEM 7.4 TILT SENSOR CALIBRATION c. Tilt sensor has developed an offset shift: Remove the tilt sensor from the Ground Con- Be sure that the machine is parked and stowed on level trol box but keep both the tilt sensor and ground.

  • Page 135: 7.5 Tilt Sensor Electrical Evaluation

    The tilt angle in both directions should read within ±0.5° while on a level surface. If not, This basic check using the JLG Analyzer can be used to then either the machine has a drifting tilt sensor or has test the Tilt Sensor.

  • Page 136: 7.7 Elevation Sensor Calibration

    SECTION 7 - JLG CONTROL SYSTEM 7.7 ELEVATION SENSOR CALIBRATION 1. Be sure that the machine is parked and stowed on level ground. 2. Attach the analyzer near the ground control sta- tion. 3. Go to Access Level 1 and scroll through to CALI- BRATION.

  • Page 137: Section 8 - Diagnostic Trouble Codes

    2210 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL ..............................6-6 2232 FUNCTION PROBLEM - DRIVE & LIFT BOTH OPEN..............................6-6 231 FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED ............................6-6 232 GROUND LIFT UP / DOWN ACTIVE TOGETHER ................................6-6 3121222 – JLG Lift –...
  • Page 138 444 LSS BATTERY VOLTAGE TOO LOW ....................................6-12 446 LOGIC SUPPLY VOLTAGE OUT OF RANGE.................................6-12 4421 LOGIC SUPPLY VOLTAGE OUT OF RANGE ................................6-12 4422 LOGIC SUPPLY VOLTAGE OUT OF RANGE ................................6-13 661 CANBUS FAILURE - POWER MODULE ..................................6-13 – JLG Lift – 3121222...
  • Page 139 9964 POWER MODULE FAILURE - INTERNAL ERROR..............................9-20 9969 POWER MODULE FAILURE - INTERNAL ERROR..............................9-20 9970 POWER MODULE FAILURE - INTERNAL ERROR..............................9-20 9971 POWER MODULE FAILURE - INTERNAL ERROR..............................9-20 99143 POWER MODULE FAILURE - INTERNAL ERROR ..............................9-20 3121222 – JLG Lift –...
  • Page 140 99145 POWER MODULE FAILURE - INTERNAL ERROR..............................9-21 99146 POWER MODULE FAILURE - INTERNAL ERROR..............................9-21 99147 POWER MODULE FAILURE - INTERNAL ERROR..............................9-21 99148 POWER MODULE FAILURE - INTERNAL ERROR..............................9-21 99149 POWER MODULE FAILURE - INTERNAL ERROR..............................9-21 – JLG Lift – 3121222...

  • Page 141: Dtc Check Tables

    • Backprobing ground board J1-18 should show about 0 volts. • Backprobing ground board J1-10 should show about 0 volts. • Calibrate the elevation sensor, see Section 5.5. • Calibrate the tilt sensor, see Section 5.2. 3121222 – JLG Lift –...

  • Page 142: 2-1 Power-Up

    • Disconnect the horn switch ribbon cable on the platform board. If DTC HORN PERMANENTLY ing power-up in platform mode. still present, replace the platform board. If DTC 221 is no longer present, SELECTED replace the horn switch or platform board. – JLG Lift – 3121222...

  • Page 143: Function Problem - Indoor / Outdoor Permanently Selected

    • Check the trigger switch signal and wiring to the platform board. The trig- TRIGGER PERMA- during power-up in platform ger input (24V) is from platform board terminal J1-1, and its output (24V NENTLY CLOSED mode. when closed) is to platform board terminal J1-8. • Replace platform board. 3121222 – JLG Lift –...

  • Page 144: 2-3 Ground Controls

    J1-15, and its ground is to ground board terminal J1-16. • Replace the ground board. 252 ELEV ANGLE SENSOR • Calibrate the elevation angle sensor to clear fault. See Section 5.5. The elevation angle sensor has HAS NOT BEEN CALI- not been calibrated. BRATED – JLG Lift – 3121222...

  • Page 145: Drive Prevented - Charger Connected

    (24V when closed) is to ground board terminal J1-20. • Replace ground board. 259 MODEL CHANGED - • Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER. The model selection has been HYDRAULICS SUS- • Replace ground board. changed. PENDED - CYCLE EMS 3121222 – JLG Lift –...

  • Page 146: 3-1 Line Contactor Open Circuit

    • Check continuity between contactor connector pin 2 and power module 12 position connector terminal 8. • Measure voltage between power model B+ and B- terminals. If 24V is present, replace line contactor. • Replace power module. 8-10 – JLG Lift – 3121222...

  • Page 147: 3-3 Ground Output Driver

    24V from ground board J1-21, and its ground is to ground board J1-30, CUIT left solenoid during normal operation. • Inspect the wiring for physical damage. • Replace ground board. 3121222 – JLG Lift – 8-11...

  • Page 148: Steer Right Short To Battery

    • Voltage from an external source was detected on the Negative Main Line LINE CONTACTOR COIL - SHORT TO Drive, Lift and Steer Prevented Contactor. BATTERY • ZAPI - HEALTH (Status LED) - ON 8-12 – JLG Lift – 3121222...

  • Page 149: Thermal Limit (Soa)

    POWER MODULE CUR- module has reached thermal > DIAGNOSTICS -> PUMP -> PUMP CUR over 130 Amps with an empty RENT LIMIT limit. deck. • Refer to Pump Motor Electrical Evaluation in Section 4.8. 3121222 – JLG Lift – 8-13...

  • Page 150: 4-4 Battery Supply

    J1-31 to power module connector socket 10 should have continu- power module. ity. Ground board socket J1-32 to power module connector socket 11 should have continuity. • Turn on machine in platform mode. If DTC 662 is present, troubleshoot that DTC before continuing. 8-14 – JLG Lift – 3121222...
  • Page 151 • Turn on machine in platform mode. If DTC 662 is present, troubleshoot ule. that DTC before continuing. • Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288. 3121222 – JLG Lift – 8-15...

  • Page 152: 6-7 Accessory

    <0.5V) for 240mS. This is caused by a stalled pump motor, a power Drive, Steer, and Lift Prevented POWER WIRING ERROR wiring issue, or a System Module malfunction. • ZAPI - HEALTH (Status LED) - ON 8-16 – JLG Lift – 3121222...

  • Page 153: 8-1 Tilt Sensor

    • Check tilt sensor connections and wiring in ground control box. SENSOR - NOT CON- No signal from tilt sensor. • Calibrate the tilt sensor, see Section 5.2. NECTED OR FAULTY • Replace then calibrate tilt sensor, see Section 5.2. 3121222 – JLG Lift – 8-17...

  • Page 154: 8-2 Platform Load Sense

    IMPROPER 9910 FUNCTION LOCKED • Reprogram platform board. The platform board software OUT - PLATFORM MOD- version is not compatible with ULE SOFTWARE VER- the rest of the system. SION IMPROPER 8-18 – JLG Lift – 3121222...
  • Page 155 • Refer to Power Module Electrical Evaluation in Section 3.6. manded. 9924 The control system's memory • Use the JLG analyzer to adjust all machine setup and personality settings, FUNCTIONS LOCKED indicates that the vehicle has refer to 5.7 Machine Configuration Programming Information.
  • Page 156 • The System Module’s VMN feedback voltage to the interface and power POWER MODULE FAILURE - PCB’s disagrees. Drive, Steer, & Lift Prevented INTERNAL ERROR • Cycle machine, if error still exists, replace System Module. • ZAPI - HEALTH (Status LED) - FLASHING 8-20 – JLG Lift – 3121222...
  • Page 157 • The System Module encountered an unexpected software issue. POWER MODULE FAILURE - Drive, Steer, & Lift Prevented • Cycle machine, if error still exists, replace System Module. INTERNAL ERROR • ZAPI - HEALTH (Status LED) - FLASHING 3121222 – JLG Lift – 8-21...
  • Page 158 SECTION 8 - DIAGNOSTIC TROUBLE CODES NOTES: 8-22 – JLG Lift – 3121222...

  • Page 159: Section 9 - General Electrical Information & Schematics

    IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRES- SURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS.

  • Page 160: Voltage Measurement (Dc)

    • Circuit power must be turned OFF before testing resistance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads – JLG Lift – 3121222...

  • Page 161: Continuity Measurement

    (See multi meter’s operation manual) • Use firm contact with meter leads • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity 3121222 – JLG Lift –...

  • Page 162: Continuity Measurement Over Long Distances

    One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure. – JLG Lift – 3121222...

  • Page 163: Electrical Switch Testing

    Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do not require contact, and must be energized to actuate.

  • Page 164: Automatic Switches

    Also, the technician can measure the voltage at both power terminals with respect to battery ground. The difference between those two measurements is the voltage applied to the load. – JLG Lift – 3121222...

  • Page 165: Applying Silicone Dielectric Compound To Amp Connectors

    2.Pierce one of the unused wire seals to allow the trapped air inside the housing to escape. 3.Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it. AMP Connector 3121222 – JLG Lift –...

  • Page 166: Assembly

    3.After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the lock- ing latches by squeezing them inward (See Connector Assembly Figure 3). 4.Slide the wedge lock into the housing until it is flush with the housing (See Connector Assembly Figure 4). Connector Assembly Figure 2 – JLG Lift – 3121222...
  • Page 167 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Connector Assembly Figure 3 Connector Assembly Figure 4 3121222 – JLG Lift –...

  • Page 168: Disassembly

    The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies the effectiveness of the connector seals and could result in system failure. 9-10 – JLG Lift – 3121222...

  • Page 169: Connector Installation

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-5. Connector Installation 3121222 – JLG Lift – 9-11...

  • Page 170: Working With Deutsch Connectors

    1.Grasp contact about 25mm behind the contact crimp barrel. 2.Hold connector with rear grommet facing you. 3.Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. 9-12 – JLG Lift – 3121222...

  • Page 171: Hd30/Hdp20 Series Disassembly

    Example of "X" connector usage nomenclature: [X006.21] refers to terminal 21 (pin and socket) of connector X006. [X006.21.soc] refers to the socket side of terminal 21, connector X006. [X006.21.pin] refers to the pin side of terminal 21, connector X006. 3121222 – JLG Lift – 9-13...

  • Page 172: Connector Loading Diagrams

    Amp 2 position plug AMP02R Amp 2 position receptacle Amp Commercial 2 position AMPC02P plug AMP04P Amp 4 position plug AMP04R Amp 4 position receptacle AMP09P Amp 9 position plug CXA08P Conxall 8 position plug 9-14 – JLG Lift – 3121222...
  • Page 173 Deutsch 14 position HD DHD14R series alum. Receptacle REA R VIEW DRC40P Deutsch 40 position plug Deutsch 2 position DT series DT02P plug Deutsch 2 position DT series DT02R receptacle Deutsch 3 position DT series DT03P plug 3121222 – JLG Lift – 9-15...
  • Page 174 A keys 10 11 12 Deutsch 12 position DT DTM12AP series mini plug with A key 10 11 12 Deutsch 12 position DT DTM12BP series mini plug with B key E06P Eaton Toggle Switch 9-16 – JLG Lift – 3121222...

  • Page 175: X-Connector Id Index

    Charger Plug X020 Charger DT06AP DT06R X021 Battery - X022 Ground Alarm DT03P X023 LH Pothole Switch X024 Left Brake DT02R DT02P X025 Right Brake DT02R DT02P X026 Contactor DT02R X027 Power Module MMF12P 3121222 – JLG Lift – 9-17...
  • Page 176 Power Module B+ from Contactor X066 Left Motor Power Mod M2 X069 Pump Motor + X070 Pump Motor - X071 Battery 1 + to Contactor X072 Battery 1 - X073 Battery 2 + X074 Battery 2 - 9-18 – JLG Lift – 3121222...
  • Page 177 1230 Footswitch Platform DT08AR X106 1230 Footswitch J1 DTM12BP X107 1230 Footswitch J2 DTM12AP X108 1230 Mast Passthru DT08AP X109 1230 Proximity Switch DT02P X110 Inverter AC input X111 Inverter AC output X112 Charger AC input 3121222 – JLG Lift – 9-19...

  • Page 178: Machine Location Of Component X-Connectors

    X089 X041 X110 X042 X111 X043 X112 X069 X008 X070 X071 X056 X072 X057 X073 X074 X012 X075 X013 X086 SEE GROUND MODULE DETAIL Figure 9-12. 1230ES - Location of Component X-Connectors on Machine. 9-20 – JLG Lift – 3121222...

  • Page 179: Es -Location Of Component X-Connectors On Ground Control Module

    X002 X001 X029 X030 X033 X034 X028 X031 X032 (1 W IRE) X035 X003 X040 X038 X010 X039 X037 X036 (2 W IRES) Figure 9-13. 1230ES -Location of Component X-Connectors on Ground Control Module. 3121222 – JLG Lift – 9-21...

  • Page 180: 9.10 Electrical Layout And Schematics

    ALARM (JA P A NESE SPEC) BEA CON LIGHT POTHOLE PROTECTION SW ITCHES DIA GNOSTIC A NAL YZER GROUND CONTROL DRIVE MOTORS Figure 9-14. 1230ES - Overview of Electrical System Components. (1600346 Drive Module) 9-22 – JLG Lift – 3121222...
  • Page 181 BA TTERY CHARGER BA TTERY INVERTER CHARGER/ POWER INVERTER SWITCH TO AC POWER CONTACTOR RELA Y PROXIMITY SENSOR LIFT CYLINDER POW ER MODULE Figure 9-14., 1230ES - Overview of Electrical System Components. (1600346 Drive Module) 3121222 – JLG Lift – 9-23...

  • Page 182: Es - Overview Of Electrical System Components. (1001092456 Drive Module)

    TANK A LA RM BEA CON LIGHT POTHOLE PROTECTION HA NDHELD A NA L YZER CONNECTION SW ITCHES GROUND CONTROL DRIVE MOTORS Figure 9-15. 1230ES - Overview of Electrical System Components. (1001092456 Drive Module) 9-24 – JLG Lift – 3121222...
  • Page 183 SWITCH TO AC POWER RELA Y DRIVE CONTROLLER PROXIMITY SENSOR –T LIFT CYLINDER + BF2 –P CONTA CTOR F1 F2 RELA Y Figure 9-15., 1230ES - Overview of Electrical System Components. (1001092456 Drive Module) 3121222 – JLG Lift – 9-25...

  • Page 184: Electrical Schematic. (Machines With 1600346 Drive Module)

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-16. Electrical Schematic. (Machines with 1600346 Drive Module) 9-26 – JLG Lift – 3121222...
  • Page 185 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870188_E Figure 9-16., Electrical Schematic. (Machines with 1600346 Drive Module) 3121222 – JLG Lift – 9-27...

  • Page 186: Electrical Schematic. (Machines With 1001092546 Drive Module)

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-17. Electrical Schematic. (Machines with 1001092546 Drive Module) 9-28 – JLG Lift – 3121222...
  • Page 187 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_F-1 Figure 9-17., Electrical Schematic. (Machines with 1001092546 Drive Module) 3121222 – JLG Lift – 9-29...

  • Page 188: Electrical Schematic. (Machines With 1001092546 Drive Module)

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-18. Electrical Schematic. (Machines with 1001092546 Drive Module) 9-30 – JLG Lift – 3121222...
  • Page 189 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_F-2 Figure 9-17., Electrical Schematic. (Machines with 1001092546 Drive Module) 3121222 – JLG Lift – 9-31...

  • Page 190: Electrical Schematic (Ground Control Module) - (Machines With 1001092546 Drive Module)

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_F-3 Figure 9-19. Electrical Schematic (Ground Control Module) - (Machines with 1001092546 Drive Module) 9-32 – JLG Lift – 3121222...

  • Page 191: 9.11 Pin Input/Output Types

    33 CAN Bus Shield Output 34 Not Used 35 Not Used 36 Not Used 37 Ground Power Output 38 Not Used 39 Master Ignition Connection Power Input Vbatt 40 Master Ground Connection Power Input 3121222 – JLG Lift – 9-33...

  • Page 192: Ground Board J3 - Connector X003

    16 Steer Right Switch Input Vbatt Table 9-7. Platform Board J3 Function Type Range (V) Ground Power Output Not Used Not Used Not Used Not Used Not Used Indoor/Outdoor Select Switch (Active Low) Input Vbatt 9-34 – JLG Lift – 3121222...

  • Page 193: Power Module - Connector X027 (1600346 Power Module)

    Not Used Not Used Not Used Not Used Not Used Line Contactor High Side Power Output Vbatt Not Used 10 CAN Bus High Input/Output Comm 11 CAN Bus Low Input/Output Comm 12 Not Used 3121222 – JLG Lift – 9-35...

  • Page 194: Power Module - J1 (1001092456 Power Module Only)

    Power Output 23 Spare Negative Reference (Connect to -B) Power Output 24 Spare Digital Input (High-Sensing) Digital Input 25 Elevation Proximity Switch (High-Sensing; 1230ES only) Digital Input 26 Charger Interlock (High-Sensing) Digital Input 27 Foot Switch (High-Sensing; 1230ES only) Digital...

  • Page 195: Power Module - J2 (1001092456 Power Module Only)

    Input 20 Spare Digital Output (Low-Side Driver) Digital Output 21 Spare Digital Output (Low-Side Driver) Digital Output 22 Negative for Overload Lamp (Low-Side Driver) Digital Output 23 Negative for Hourmeter (Low-Side Driver) Digital Output 3121222 – JLG Lift – 9-37...

  • Page 196: Battery Charger/Inverter Electrical Connection Schematic

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-20. Battery Charger/Inverter Electrical Connection Schematic 9-38 – JLG Lift – 3121222...

  • Page 197: 9.12 Ac Power Receptacles And Wiring (Platform) - Ce Spec Machines Only

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.12 AC POWER RECEPTACLES AND WIRING (PLATFORM) - CE SPEC MACHINES ONLY 3121222 – JLG Lift – 9-39...
  • Page 198 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9-40 – JLG Lift – 3121222...
  • Page 199 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3121222 – JLG Lift – 9-41...
  • Page 200 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9-42 – JLG Lift – 3121222...

  • Page 201: 9.13 Hydraulic Schematic

    SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.13 HYDRAULIC SCHEMATIC Figure 9-21. Hydraulic Diagram. (2792703_B) 3121222 – JLG Lift – 9-43...
  • Page 202 SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 9-44 – JLG Lift – 3121222...
  • Page 203 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Batteries also contain other harmful chemicals known to the State of California. WASH HANDS AFTER HANDLING!
  • Page 204 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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